Babcock Wanson (UK) Ltd

Whether you need steam, hot water or superheated water production for your process heating application, at Babcock Wanson, we offer you the best boiler house solution with high performance, low emissions and real energy optimisation. We provide:

  • Fire tube steam boilers
  • Hot water boilers
  • Coil type steam boilers
  • Waste heat recovery boilers
  • Thermal fluid heaters
  • Water-tube boilers
  1. Babcock Wanson announces launch of new CEA thermal fluid system guide
    19 February 2020

    Leading industrial process heating equipment manufacturer Babcock Wanson is pleased to announce the release of the latest Combustion Engineering Association (CEA) boiler guide – ‘Thermal Fluid Systems – A Practical Guide for Safe Design, Operation and Maintenance’ – in which it has been one of the lead authors in collaboration with other appropriate members of the CEA.

    BG07, as the new guide is referenced, has been produced to help designers, owners, managers and operators of new and existing thermal fluid heating systems to operate safe installations, and to make health and safety and environmental improvements in the industry. The objective is to help users of thermal fluid systems manage their own risks and create safe and efficient installations.

    “Babcock Wanson is proud to have been a key contributor to this document” states Chris Horsley, Process Engineering Director at Babcock Wanson.  “As a manufacturer of the full gamut of industrial process heating systems, we have extensive, invaluable experience in this field, from best practice in designing systems, through to health and safety and operational procedures.  Thermal fluid systems are increasingly popular due to their ease of use, longevity, energy efficiency and more, and, whilst they are far easier to manage than, say, a comparable steam system, understanding how they work and their parameters is important to ensure you get the most out of your investment, including energy efficiency, safety and long life.”

    ‘Thermal Fluid Systems – A Practical Guide for Safe Design, Operation and Maintenance’ covers the full range of issues pertinent to thermal fluid systems, from why and when to use them and system design considerations such as choice of fluid, heat source, expansion and deaeration,  pumps and pipework, to installation and commissioning and operation and maintenance.  Training is also addressed, along with legislative requirements.

    Babcock Wanson has worked closely with the CEA on this and other projects, including additional boiler guides and producing the first Boiler Operation Accreditation Scheme (BOAS) Cat 5 training course for Coil type Steam Generator Operators in the UK.

    The CEA is an educational charity which promotes the science of combustion engineering in the commercial and industrial sectors.  The CEA is concerned with industry good practice and the safe and efficient operation of combustion related plant and equipment, and offers guidance and accredited training schemes that match the wide range of industrial combustion plant available today.

    David Kilpatrick, Director of the CEA, has said “that without the significant input of Babcock Wanson and other members of the CEA this, and other similar guides, would not be possible, and I would hope that industry now takes up the training that is available to support this guide and understands the legislative requirements”.

    Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions.  The company aims to help optimise customer’s energy production with high quality products and efficient service.

    The new ‘Thermal Fluid Systems – A Practical Guide for Safe Design, Operation and Maintenance’ is available to order from the CEA website – https://cea.org.uk/knowledge-centre/cea-guidance-documents/ – at a cost of £50 plus P&P.

    For more information on Babcock Wanson go to www.babcock-wanson.com, call on 020 8953 7111  or email info@babcock-wanson.co.uk.

    Babcock Wanson announces launch of new CEA thermal fluid system guide
  2. Babcock Wanson produces world’s first 1MW gas fired supercritical water heater
    19 February 2020

    Babcock Wanson has produced a bespoke TPC SW 1MW gas fired Supercritical Water Heater, which operates at 275 bar pressure and reaches a temperature of 490°, for Promethean Particles as part of its nanoparticle production process.

    Promethean Particles has built the world’s largest continuous multi-material nanoparticle manufacturing plant, based in Nottingham, producing in excess of 1000 tons per year.  Its unique reactor design allows for continuous (as opposed to batch) production and flexibility, enabling it to produce a huge variety of materials to customer’s specifications.  The flexibility is largely down to the wide temperature range achievable with its process, which is important as there is a correlation between the temperature and particle size.

    Babcock Wanson was one of a handful of manufacturers approached by Promethean Particles, and the only one to provide a suitable solution.  The heater is based on a Babcock Wanson TPC 1000B, but with very special inners and controls.  For this bespoke heater Babcock Wanson designed and manufactured a specially wound continuous coil assembly to form the main heating surface using ASI 321 9mm thick stainless steel, as opposed to the usual 4mm carbon steel for a standard industrial type water heater.  The core of the tube is very small.  This material and thickness were chosen to meet the pressure and temperature demands of the process to be able to produce supercritical water at up to 250 bar and 450°C.

    Several challenges were faced along the way, including designing the heater with the ability to accept variations in water flow (between 600-3000 kg/h per hour) and heat input within quite wide parameters; developing specialist welding techniques to cope with the material to the design pressure required and specifying and installing specialist instruments and controls to work at these temperatures and pressures.

    All in all it took seven months to design and build.  The combustion system, control scheme and software were designed in-house by Babcock Wanson.  Relevant mountings, safety valves, pressure controllers and differential controllers were sourced and fitted in house to enable PED approval.  A hazard and operability study (HAZOP) were carried out between Babcock Wanson and Promethean engineers to review the controls and integration with the site control Scada system.

    The resulting heater is now an integral part of the process, which includes return fluid heat recovery to limit the final temperature rise of the fluid to 90°C.  This brings it up to 360°C water at 270 bar to take it to the temperature required for the supercritical condition.  With standard water, this would typically require just 314kW, but as the supercritical water is so dense up to 1000kW is needed.

    The supercritical water is then pumped into the reactor at the same time as the precursor where it mixes and forms the product.  The product leaves the reactor through a specially constructed section at 350°C.  It then goes through the heat exchanger to cool it down and recover waste heat and the pressure is reduced before passing the product into a holding tank.  Depending on the product, further processing may then be required.

    The entire process is controlled by sophisticated software and is encased in toughened casing for safety.

    Lewis Neve, Production Engineer at Promethean Particles, comments: “The heater is running as expected.  Babcock Wanson knew what they were doing and it went very smoothly.  They have also been very easy to work with, very professional in the way they communicated with us and the fact that they were in constant communication made it easier for us.”

    Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions.  The company aims to help optimise customer’s energy production with high quality products and efficient service.

    For more information, please contact Babcock Wanson on 020 8953 7111  or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

    Babcock Wanson produces world’s first 1MW gas fired supercritical water heater
  3. Babcock Wanson Steam Boiler for Caramel Production
    19 February 2020

    The NIGAY family company, based in FEURS (42-France), specialises in the manufacture of caramels for use in various forms by craftsmen and food processing industries (annual production of 68,000 tons).
    Driven by its dynamic growth and committed to an ISO 50001 approach, it has decided to convert its steam production equipment from heavy fuel oil to natural gas firing thereby improving both energy utilisation and performance.

    It has placed its trust in Babcock Wanson to install a new boiler room, which includes a BWD 80 steam boiler equipped with a Babcock Wanson Modulo+ micro-modulating burner and an economizer. This equipment allows the boiler to operate at very low power with a modulation range from 1 to 12, while maintaining flexibility of use, highest practicable efficiency and a very high response rate.

    The economizer recovers part of the heat from the flue gases to preheat the boiler feed water. The boiler room is controlled by a dedicated PLC, making it easy to monitor its performance and operation.

    The efficiency of the installation with this level of equipment is circa 95.6% based on the net calorific value of the fuel.. NOx emissions are of the order of 80 mg/Nm, a value well below that imposed by the site operating permit (150 mg/Nm).
    The conversion of the boiler room to natural gas has enabled the company to reduce its CO emissions by nearly 30%.

    Babcock Wanson Steam Boiler for Caramel Production
  4. BABCOCK WANSON UK expands its “OFF THE SHELF” Steam Boiler Premium Range
    28 June 2019

    Following the launch of its new Premium Range of fire tube steam boilers in 2017, Babcock Wanson UK has expanded the range with the addition of coil type steam boilers.

    The Premium Range is designed to provide customers with a boiler that meets the very latest safety and operational guidelines at an “off the shelf” price and with shortest practicable delivery time.

    The latest addition is the VAP Premium Range of fully automated coil type steam boilers with standard outputs from 150 to 1500 kg/h at a 12 bar design pressure. They are available with a range of control options.

    VAP Premium Range Coil Type Steam Boilers all feature three full gas passes, plus an in-built combustion air pre-heater to give high operating efficiency. With availability of steam from a cold start in as little as three minutes and a low volume of water under pressure VAP boilers combine efficiency with safety, even at high working pressure.

    Premium Range boilers are highly competitively priced and are aimed at the steam user who wants fully automated control with the minimum of boiler house manning.

    BABCOCK WANSON UK expands its “OFF THE SHELF” Steam Boiler Premium Range
  5. BABCOCK WANSON boiler installed in a metals surface finishing company
    28 June 2019

    Babcock Wanson has supplied a NBWB150 PREMIUM fire tube boiler for a French company specialising in electrolytic and chemical surface finishing of metals. The new boiler is being used to heat the surface treatment baths, drying ovens and general plant.

    This major investment ensures a secure and continuous industrial process and helps our customer save energy whilst at the same time improving the overall operating efficiency and production capacity.

    BABCOCK WANSON boiler installed in a metals surface finishing company
  6. 3 Boilers to Coca Cola in France
    4 July 2018

    COCA COLA wishing to increase the production capacity of the SOCX site (59) entrusted BABCOCK WANSON with the order for 3 BWD 60 boilers in BW 7 DAYS.

    This order comes with a BW e-Manage and a 10-year warranty extension.

    Our long history with this site (the current boilers are from 1989) and the service provided for many years made it possible to concretize this file despite the competition with other manufacturers.

    3 Boilers to Coca Cola in France
  7. BABCOCK WANSON boiler installed in new £11m Board Manufacturer Plant
    4 May 2017

    BABCOCK WANSON boiler installed in new £11m Board Manufacturer Plant

    s part of a £11m investment in its Preston plant, corrugated sheet board manufacturer Board24 has installed a BABCOCK WANSON BWD60 fire tube boiler, which is being used to provide steam for a new bespoke volume corrugator. 

    Previously, Board24 was toiling at peak times to satisfy customer demand. With the site and new equipment - including the BWD60 fire tube boiler - up and running, Board24 has now doubled its capacity. 

    This major investment was recently recognised at the UK Packaging Awards 2016 where Board24 was Highly Commended in the Investment Project of the Year category .

    The BWD60 was supplied by BABCOCK WANSON Espana and commissioned by BABCOCK WANSON UK, which is also providing a service contract consisting of one full and one burner service per year.

    Lee Bullen, Corrugated Services Manager at Board24, is pleased with the outcome: “It’s running very well, both easy to use and efficient. The service from Babcock Wanson has also been very good.”

    BABCOCK WANSON boiler installed in new £11m Board Manufacturer Plant

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